Connector

ABSTRACT

A connector having a contact element for making an electrical connection between a continuing or run wire and a tap wire terminating in the connector. The walls of the connector define a channel with an open side to fit over a length of the run wire in a position for engagement by the contact element, and the connector includes a retaining wall mounted for movement to a latched position across the open side of the channel to retain the run wire therein in proper position for engagement by the contact element.

United States Patent 1 Johansson etal.

[451 Feb. 19,1974

CONNECTOR lnventors: Ronald C. Johansson, Lake St.

Croix Beach; Norman P. Vogel, White Bear Lake, both of Minn.

Minnesota Mining and Manufacturing Company, St. Louis, Mo.

Filed: Mar. 2, 1972 Appl. No.: 231,229

Assignee:

US. Cl. 339/98 Int. Cl H0lr 9/08 Field of Search 339/59-61, 95,

References Cited UNITED STATES PATENTS 6/1968 Elm 339/98 4/1972 Seim 339/98 3,656,088 3,118,7l5 l/l964 Potruch 3,500,292 3/1970 Enright et al. 339/97 R Primary Examiner-Joseph H. McGlynn Attorney, Agent, or FirmAlexander, Sell, Steldt & DeLaHunt [57] ABSTRACT I A connector having a contact element for making an electrical connection between a continuing or run wire and a tap wire terminating in the connector. The walls of the connector define a channel with an open side to fit over a length of the run wire in a position for engagement by the contact element, and the connector includes a retaining wall mounted for movement to a latched position across the open side of the channel to retain the run wire therein in proper position for engagement by the contact element.

10 Claims, 5 Drawing Figures I CONNECTOR FIELD OF THE INVENTION This invention relates to spring compression reserve electrical connectors, and in particular to connectors making permanent electrical contact with an insulated run wire.

DESCRIPTION OF THE PRIOR ART Attaching prior art spring compression reserve connectors to make an electrical connection to a length of a continuing or run wire (i.e., a wire that does not terminate at the connector has presented certain difficulties and problems. Some prior art connectors when not attached consist of separate body portions, one of which supports the contact element,vsuch as the connector disclosed in U.S. Pat. No. 3,5 l 1,921. Attached connector of this type requires coordinating the location of a run wire and the separate body portions, and assembling the connector body portion about the wire.

No. 3,1 l8,7l5, have body members which assembled prior to attachment and have parts which are relatively movable to complete the connection. While being relatively easy to use, connectors of this type require pressing a contact element into engagement with a run wire positioned in a channel having an open side. The open side affords the possibility of incorrect placement of the run wire during engagement of the contact element resulting in a defective electrical connection.

SUMMARY or THE INVENTION 'The present invention provides a connector useful for making an electrical connection to an insulated run wire. The connector, which is aone piece assembly prior to attachment, has a channel having an open side for receiving a length of the run wire. The connector includes a wall which may be latched in position across the open side of the channel to retain and properly position awire for subsequent engagement by a contact element. 1

According to the present invention there is provided a' connector of the type having a resilient conductive contact element with spaced wire engaging fingers, and an insulating body member having-spaced projecting walls defining a channel with an open side for receiving a length of run wire. A slot extends from a top surface on the body member transverse of the channel and slidably receives the contact element for movement from a first position spaced from the channel to afford positioning a length of the run wire therein, to a second engaged position with the fingers extending across the channel to engage a run wire in the channel. The im proved connector according to the present invention includes a retaining wall pivotally mounted along one edge thereof to the end of one of the walls for movement from an open position spaced from the open side of the channel to afford positioning a run wire in the channel, to a closed position across the open side at which the retaining wall is retained by latching means to retain said run-wire in the channel in a proper position for engagement by the contact element.

The connector also includes a cover mounted for movement from an open position affording access to the top side of the connector to press the contact element to its second position in engagement with a run Other connectors such as the connector of U.S. Pat. 1

wire in the closed channel, to a closed position over the top surface to cover the end of the engaged contact element.

BRIEF DESCRIPTION OF THE DRAWING The invention will be more .fully understood by a careful reading of the following description which refers to the accompanying drawing in which:

FIG. 1 is a view in perspective of a connector according to the present invention, showing the retaining wall and cover open and the contact element for the connector separated therefrom;

FIG. 2 is a top plan view of the connector of FIG. 1 shown with the retaining wall and cover open, and with the contact element in engagement with a pair of wires in the connector;

FIG. 3 is a cross sectional view taken approximately along lines 3-3 of FIG. 2 but shown with the retaining wall and the cover closed;

FIG. 4 is a front end view of the connector in FIG. 1 shown with the retaining wall closed and the cover open; and

FIG. 5 is a rear end view of the connector in FIG. 1 shown with the retaining wall and the cover closed.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawing there is shown a'connector 10 according to the present invention having a U-shaped conductive contact element 12 with spaced planar parallel legs having parallel aligned slots formed therein to provide spaced wire engaging fingers l4, and an insulating body member 16. The body member 16 is formed with a cavity 18 for receiving the end of a tap wire 17 (i.e. a wire which terminates in the connector) extending longitudinally into the body member through an inlet opening 20 in the end wall 19 toward an opposite end wall 21. The cavity communicates with a first or top surface 23 of the body member 16 through an opening 22 between the end walls 19 and 21 to afford direct visual observation of the position of a wire within the cavity 18 prior to, during, an subsequent to engagement by the contact element 12. The connector 10 is formed along one side with a generally U-shaped channel 24 positioned parallel to the cavity 18 and extend ing through both end walls 19 and 21. The channel 24 has an open side along one side of the connector 10 defined by spaced cantilevered wall members or'projecting walls 26 and 27 for receiving a length of a continuing or run wire 28. The body member 16 is formed with a pair of slots 30 extending transverse to the cavity 18 and channel 24 from the top surface 23 on the body member 16. The slots 30 slidably receive the contact element 12 for movement between a first position (FIG. 4) with the fingers 14 spaced from the cavity 18 and channel 24 to afford positioning wires therein, to a second engaged position (FIG. 3) within the slots 30 at which the fingers 14 extend across the cavity 18 and the channel 24 to engage wires therein.

The connector 10 includes a retaining wall 34 attached along one side thereof by a first hinge portion 36 to the end of the projecting wall 26. A cover 38 is attached along the opposite edge of the retaining wall 34 by a second hinge portion 40. The first hinge portion 36 affords movement of the retaining wall 34 relative to the body member 16 from an open position spaced from the opening of the (FIGS. 1 and 2) toallow insertion of a length of a run wire; to a closed position between the walls 26 and 27 (FIGS. 3, 4, and 5) at which the retaining wall 34 is retained by a latching means later to be explained. In the closed position the retaining wall 34 closes the open side of the channel 24, properly positions the wire within the channel 24 for engagement by the contact element 12, and provides support between the walls 26 and 27 during movement of the contact element 12 to its engaged position.

The connector also includes means for restricting movement of a run wire within the channel 24. The retaining wall 34 includes a projection 39 having an arcuate surface and sized to press into the insulation of a run wire in the channel 24 to restrict its rotational and axial movement when the retaining wall 34 is in the closed position. The projection 39 is positioned along the retaining wall 34 to move between the slots 30 for the contact element 12 when the retaining wall 34 is engaged, and the ends of the projection are planar and spaced to guide the contact element 12 as it is moved to its engaged position. 1

. When the retaining wall 34 is in the closed position, the second hinge portion 40 affords movementof the cover 38 relative to the retaining wall 34 and body member 16 from an open position (FIG. 4) with a' second surface 41 on the cover 38 spaced from the top surface 23 on the body member 16 to afford access to the contact element 12 to move it to its engaged position; to av closed position (FIG. 5). In the closed position of the cover 40 a flexible hook-like edge wall 42 parallel to and opposite the second hinge portion 40 is in engagement over a lip 43 and the second surface 41 is in contact with the top surface 23 over the opening 22 and the end of the engaged contact element 12 to provide electrical insulation over the wire end in the cavity 18 and over the exposed surface of the contact element 12. v

The body member 16, the first and second hinge portions 36 and 40, the retaining wall 34, andthe cover 40 are a one piece molding of a polymeric material, a preferred material being polypropylene. As molded, the retaining wall 34 and cover 38 projectfrom the body member 16 as illustrated in FIGS. land 2. The first and second hinge portions 36 and 40 are parallel and are each defined by a generally V-shaped groove 44, each groove being defined by a pair of converging walls 45. The grooves 44 reduce the thickness of the hinge portions 36 and 40 to no greater than 0.030 inch (preferably about 0.015 inch) along precisely located narrow strips 46 at the base of the grooves 44. The plastic material in the strips 46 will deform to allow movement of the retaining wall 34 relative to the body member 16, and movement of the cover 40 relative to the retaining wall 34. Movement of the retaining wall 34 to the closed position and subsequent movement of the cover 38 to the closed position will deform the strips 46 and move the walls 45 of each groove 44 toward a contacting position. Thus the walls 45 of each groove 44 are disposed at an angle of at least 90 to each other when the retaining wall 34 and cover 38 are in the open position as illustrated in FIGS. 1 and 2 to allow the closed position of the retaining wall 34 to be determined by contact with the wall 27, and the closed position of the cover 38 to be determined by contact between the surfaces 41 and 23.

The connector 10 includes latching means for latching the retaining wall 34 in the closed position, and for latching the cover 38 in the closed position.

The precisely located lineof bending afforded by the strips 46 between the body member 16 and the retaining wall 34 provide accurate positioning of an arcuate surface 51 on a hook-shaped longitudinally extending projection 47 on the retaining wall 34 which will contact an arcuate surface 48 on the wall 27 when the retaining wall 34 is moved toward the closed position. Further pressure to move the retaining wall 34 to the closed position will cause a camming action between the arcuate surfaces 48 and 51 to deflect the walls 26 and 27 of the channel 24 and allow the projection 47 to seat in a mating furrow 49 formed along the inner surface of the wall 27 to latch the retaining wall 34 in the closed position. In its closed position the retaining wall 34 will support and properly space the walls 26 and 27 during engagement of the contact member 12 with a pair of wires.

With the retaining wall 34 in the closed position, the precisely located line of bending afforded by the strip 46 between the retaining wall 34 and the cover 38 provides accurate positioning of the edge wall 42 when the cover has moved toward the closed position so that an arcuate surface 50 on the edge wall 42 will contact an arcuate surface 52 on the lip 43 Further pressure on the cover 38 to move it to its closed positionwill cause a camming action between the arcuate surfaces 50 and 52 and deflection in the edge wall 42 and second hinge portion 40 so that the edge wall 42 will move over the lip 43 into latching engagement therewith to maintain the cover 38 in the closed position.

The connector 10 also provides means to retain the insulated end of a tap wire in the cavity 18 prior to engagement of the contact element 12. The inlet opening 20 provides clearance about the end of a tap wire for whichthe connector 10 is sized to afford ease of entrance for a tap wire inserted into the cavity 18. The width of the cavity 18 narrows along a tapered wall portion 54 (FIG. 2) to direct the end of the inserted tap wire into the portion of the cavity 18 from the tapered wall portion 54 to the end wall 21. The portion of the cavity 18 from the tapered wall portion 54 to the end wall 21 is sufficiently narrow to insure proper lateral positioning of the tap wire for engagement by the contact element 12 and to provide a light press fit with the end of the inserted tap wire. This light pressfit will restrict accidental extraction of the tap wire from the cavity 18 prior to engagement thereof by the contact element 12, which is advantageous to a craftsman to allow him to direct his attention to other manipulation required to attach the connector 10.

Having thus described the present invention, what is claimed is:

1. In a connector for making an electrical connection to an insulated run wire, said connector comprising a resilient conductive contact element having spaced wire engaging fingers; and an insulating body member having spaced projecting walls defining a longitudinally extending channel through said connector with an open side for receiving a length of a run wire, and a slot extending from a first surface on said body member transverse of said channelslidably receiving said contact element for movement from a first position spaced from said channel to afford positioning a wire therein, to an engaged position with said fingers extending across said channel to engage a wire therein, the improvement wherein: 1

said connector includes a retaining wall of sufficient width to extend between the ends of said projecting walls; means hingedly mounting said retaining wall along a first edge thereof to the end of one of said projecting walls adjacent said open side for pivotal movement from an open position spaced from the open side of said channel to a closed position with the width of said wall extending across the open side of said channel, said wallbeing shaped to contact the adjacent side of a wire in said channel when said retaining wall is in the closed position to retain and properly position the wire in the channel for engagement by the contactelement; and latching means engageable between said retaining wall and the other of said projecting walls for latching said retaining wall in said closed position. 2. A connector according to claim 1 wherein said connector further includes a cover sized to extend over said first surface, means pivotally mounting the cover along one edge thereof to said body member for movement relative to said body member from an open position spaced from said first surface to a closed position over said first surface when said contact element is in said engaged position, and latching means engageable between said cover and said body member for latching said cover in said closed position.

3. A connector according to claim 1 further including a cover having a second surface shaped to extend over said first surface, means pivotally mounting the cover along one edge thereof to the edge of said retaining wall opposite said first edge for relative movement when said retaining wall is in said closed position from I an open position with said second surface on said cover spaced from said first surface on said body member to afford access to said contact element to move said contact element from said first to said engaged position, to a closed position when said contact element is in said engaged position with said second surface contacting said first surface to cover said contact element, and latching means engageable between said cover and said body member for latching said cover in said closed position.

4. A connector according to claim 3 wherein said body member, said retaining wall and said cover are a one piece molding of a polymeric material, and said means pivotally mounting said cover and said body member to said retaining wall comprise thin narrow strips of said polymeric material no greater than 0.030 inch thick, said attaching strips being deformable to afford said relative pivotal movement of said retaining wall and said cover from said open to said closed positions.

5. A connector according to claim 3 wherein said polymeric material is polypropylene.

6. A connector according to claim 3 wherein said connector has a cavity for receiving the end of a wire and extending from an inlet opening to an end wall on said body member, said slot extends from said first surface transverse of said cavity, and said contact element has fingers adapted to extend across and engage a wire in said cavity when said contact element is moved to said engaged position to connect a wire in said cavity to a wire positioned in said channel.

7. A connector according to claim 6 wherein said connector further includes means for frictionally retaining a wire in said cavity prior to movement of said contact element to said engaged position.

8. A connector according to claim 1 wherein said connector has a cavity for receiving the end of a wire and extending from an inlet opening to an end wall on said body member, said slot extends from said first surface transverse of said cavity, and said contact element has fingers adapted to extend across and engage a wire in said cavity when said contact element is moved to said engaged position to connect a wire in said cavity to a wire positioned in said channel.

9. A connector according to claim 1 wherein said connector further includes means for restricting rotational and axial movement of a wire in said channel when said retaining wall is in said closed position and before said contact element is moved to said engaged position.

10. A connector according to claim 1 wherein said retaining wall includes a projection formed for engagement with a wire in said channel when said retaining wall is in said closed position to restrict axial movement of said wire along said channel, and rotational movement of said wire within said channel.

Patent No. 3,793,611 Dated February 19, 191

Inventor(s) Ronald C. Johansson I It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

The correct address of the Assignee is St. Paul, Minnesota.

Column 1, line 1 after "connector" insert line 18, change "Attached" to Attaching a and line 23, after "which" insert are a Column 2, last-line, after "the" '(second occurrence) 3 insert channel 24 Column 3, line 31, change "cover +0" to cover 38 line +1, change "cover #0" to cover 38 and line 55, change "cover #0" to cover 38 Signed and sealed this 10th day of September 1974.

(SEAL) Attest:

McCOY M. GIBSON, JR. c. MARSHALL DANN Attesting Officer Commissioner of Patents FORM pd'wso $59) 7 v uscoMM-oc 6037641 ".5. BOVIIIIIIT 'IIIITI OIIICI 2 I. 0-60-38.

UNITED STATES PATENT OFFICE I CERTIFICATE OF CORRECTION Patent No. 5,793,611 Dated February 19, 191A Inventor(s) Ronald C. Johansson o "-4 It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

The correct address of the Assignee is St. Paul, Minnesota.

Column 1, line l after "connector" insert line 18, change "Attached" to Attaching a and line 23, after "which" insert are Column 2, last'line, after "the" (second occurrence) insert channel Zh- Column 3, line 31, change "cover #0" to cover 58 line +1, change "cover #0" to cover 38 and line 55, change "cover +0" to cover 58 Signed and sealed this 10th day of September 197k.

(SEAL) Attest:

McCOY M. GIBSON, JR. C. MARSHALL Attesting Officer Commissioner of Patents FORM PO-IOSO (1069) USCOMM-DC dean-Poo 9 .5. GOVEINIINT PRI NYIIG OPTIC! II. O-JFm 

1. In a connector for making an electrical connection to an insulated run wire, said connector comprising a resilient conductive contact element having spaced wire engaging fingers; and an insulating body member having spaced projecting walls defining a longitudinally extending channel through said connector with an open side for receiving a length of a run wire, and a slot extending from a first surface on said body member transverse of said channel slidably receiving said contact element for movement from a first position spaced from said channel to afford positioning a wire therein, to an engaged position with said fingers extending across said channel to engage a wire therein, the improvement wherein: said connector includes a retaining wall of sufficient width to extend between the ends of said projecting walls; means hingedly mounting said retaining wall along a first edge thereof to the end of one of said projecting walls adjacent said open side for pivotal movement from an open position spaced from the open side of said channel to a closed position with the width of said wall extending across the open side of said channel, said wall being shaped to contact the adjacent side of a wire in said channel when said retaining wall is in the closed position to retain and properly position the wire in the channel for engagement by the contact element; and latching means engageable between said retaining wall and the other of said projecting walls for latching said retaining wall in said closed position.
 2. A connector according to claim 1 wherein said connector further includes a cover sized to extend over said first surface, means pivotally mounting the cover along one edge thereof to said body member for movement relative to said body member from an open position spaced from said first surface to a closed position over said first surface when said contact element is in said engaged position, and latching means engageable between said cover and said body member for latching said cover in said closed position.
 3. A connector according to claim 1 further including a cover having a second surface shaped to extend over said first surface, means pivotally mounting the cover along one edge thereof to the edge of said retaining wall opposite said first edge for relative movement when said retaining wall is in said closed position from an open position with said second surface on said cover spaced from said first surface on said body member to afford access to said contact element to move said contact element from said first to said engaged position, to a closed position when said contact element is in said engaged position with said second surface contacting said first surface to cover said contact element, and latching means engageable between said cover and said body member for latching said cover in said closed position.
 4. A connector according to claim 3 wherein said body member, said retaining wall and said cover are a one piece molding of a polymeric material, and said means pivotally mounting said cover and said body member to said retaining wall comprise thin narrow strips of said polymeric material no greater than 0.030 inch thick, said attaching strips being deformable to afford said relative pivotal movement of said retaining wall and said cover from said open to said closed positions.
 5. A connector according to claim 3 wherein said polymeric material is polypropylene.
 6. A connector according to claim 3 wherein said connector has a cavity for receiving the end of a wire and extending from an inlet opening to an end wall on said body member, said slot extends from said first surface transverse of said cavity, and said contact element has fingers adapted to extend across and engage a wire in said cavity when said contact element is moved to said engaged position to connect a wire in said cavity to a wire positioned in said channel.
 7. A connector according to claim 6 wherein said connector further includes means for frictionally retaining a wire in said cavity prior to movement of said contact element to said engaged position.
 8. A connector according to claim 1 wherein said connector has a cavity for receiving the end of a wire and extending from an inlet opening to an end wall on said body member, said slot extends from said first surface transverse of said cavity, and said contact element has fingers adapted to extend across and engage a wire in said cavity when said contact element is moved to said engaged position to connect a wire in said cavity to a wire positioned in said channel.
 9. A connector according to claim 1 wherein said connector further includes means for restricting rotational and axial movement of a wire in said channel when said retaining wall is in said closed position and before said contact element is moved to said engaged position.
 10. A connector according to claim 1 wherein said retaining wall includes a projection formed for engagement with a wire in said channel when said retaining wall is in said closed position to restrict axial movement of said wire along said channel, and rotational movement of said wire within said channel. 